Sound absorbing material



March 17, 1936- w. A. MCMILLAN SOUND ABSORBING MATERIAL Filed 0G13. 19, 1955 Patented Mar. 17, 1936 UNITED STATES PATENT OFFICE to Burlington Mills,

Incorporated, Burlington,

Wis., a corporation of Wisconsin Application Octoberv19, 1935, Serial No. 45,695 6 Claims. (Cl. 154-44) 'I'his invention relates to a new and improved insulating and sound absorbing material characterized as comprising a vfelted sheet or strip having a finished, decorative surface of pleasing and ornamental appearance which is adapted for various uses, and particularly, as panels or similar pieces for lining automobile bodies and the like.

This invention also relates to a process for 10 producing the material of this invention and for producing lining panels made from said material.

Automobiles as now constructed usually have metallic bodies. Such bodies are strong, safe and generally more desirable, except for the fact that they are noise producing when the car is in motion. 'I'he motion of the car over the usual irregularities of the roadicauses such bodies to give off a rumbling and drumming noise which necessitates for their successful use, the application thereto of some suitable sound deadening material.

This objection to metallic bodies, and especially metallic bodies of modern design of the streamline or semi-streamline type has retarded to some extent, the natural and desired development of metallic bodies buttheproblem has now been met by the use of certain lining materials, usually felted sheets, applied generally to the interior of a body by means of a suitable adhesive such as asphaltic or other adhesive materials.

In addition to the sound deadening effect such lining materials also have the property of heatv insulation, which becomes more important with metallic walls, and particularly now, when cars are sometimes equipped with heating and cooling devices.

Such felted materials are usually relatively cheap, formed from jute or similar fibers and as applied to the body, leave an unsightly appearance, necessitating a further covering of a suitable finishing material such as leather, imitation leather, mohair or other suitable cloth or iinishing material. y

It will thus be seen that the finishing of the usual automobile body requires not only the application of the sound deadening felt material -but also a covering material which provides the pleasing and decorative nish referred to. 'I he finishing material is not only expensive but necessitates la separate applying operation which adds to the manufacturing time and expense.

Furthermore, with cars of modern design, there is usually provided a great deal of space, particularlyA in the rear compartment thereof, which is utilized for rumble seats, luggage space and be made.

similar purposes. This space likewise must be covered with sound deadening material and similarly finished to provide the desired pleasing appearance. Inasmuch, however, as the rear and other compartments referred to, usually are not a direct part of the passenger compartment of the car, it is not essential to employ the same expensive nishing materials usually applied to the passenger compartment. It is only necessary to employ a. material possessing the sound deaden- 10 ing property which itself may have a satisfactory pleasing finished appearance.

A material of this latter type capable of being applied to the interior of the walls in a single operation, as panels if desired, without requiring 15 an additional finishing or covering material to be applied thereover, would supply a great need in the industry and provide a solution for the above enumerated problems in acheap and economical manner. 20

Accordingly, the material of this invention is particularly adapted for such use although it may be used throughout the entire interior of cars if. such should prove desirable.

The material of this invention comprises es- 25 sentially a body strip or sheet composed of a felted, matted layer of fibers such as jute or hair fibers, which have been suitably carded or combed and punched through a backing strip of burlap or other suitable material.- This is a well known 30 form of felt which is now produced in large quantities and which serves admirably as a base sheet from which the material of this invention may y 'I'he method of manufacture of this felt is understood and known in the art and 35 therefore a detailed description will not be here given. However, it is known that the felted mat is applied to the burlap backing strip by punching the mat of fibers through the burlap by suitable needles which cause certain of the 40 fibrous material to extend through the nterstices of the burlap strip and, in this manner, to become locked to the strip.

In accordance with the present invention, the felted material so prepared, while in a soft, flexi- 45 ble condition, is subjected to a printing operation, as by rollers or other suitable printing devices which apply to the burlaprsurface thereof, a desired marking in one or more colors and/or designs, with the result that the visual effect of the 50 printed marking superimposed on the visible woven threads of the burlap give to the whole, the appearance of a woven cloth of heavy and good quality and of pleasing and attractive appearance. For instance, by applying to such burlap 55 surface, a thin diagonal slash of some desired contrasting or blending color, the natural weave of the burlap fabric together with the slash marking gives to the material an appearance somewhat similar to that of an expensive and heavy woven cloth. The markings may be of any desired type, as for instance, instead of a diagonal slash the marking may be of a herringbone or other typical style of weave, which will impart to the material, the appearance of a heavy woven cloth of desired pattern. Furthermore, an additional marking such as a relatively large plaid stripe in one or more colors may be superimposed on the rst mentioned marking so as to provide an imitation of plaid or striped cloth.

In addition to the above markings, the appearance may be further developed by iirst dying or otherwise coloring the burlap so as to give to it a desired blending or contrasting color with respect to the printed markings to be applied thereto. In such cases the burlap backing may be dyed a color which either blends with or is in contrast to the cross slashes or other markings in the desired way to produce a desired nished appearance.

In addition to the above methods of providing desirable appearance eiects, the fiber itself may likewise be colored in the same manner that the burlap strip is colored. Thus the burlap and attached bers maybe dyed or colored the same color and/or shade, or of a contrasting color and/or shade. By providing different colors for the fibers and burlap backing strip a very pleasing mixed woven fabric appearance is imparted to the material according to the selection of the colors employed. This material then lends itself well to the subsequent marking by the printing operation which imposes thereon a striped, herringbone, plaid or other effect, in one or more colors.

In this way, as a result of colors, the materials employed, the printed markings thereon, and the visible woven threads of the burlap, a large variety of very pleasing surface effects may be produced all of which simulate in appearance, the appearance of heavy and expensive woven fabrics of desirable and pleasing patterns. Such material isv admirably suited for lining and nishing uses such as the lining of automobile bodies, because in addition to its finishing eiect, it has good sound deadening qualities as well as the property of insulating against heat transfer.

After printing the material as above described and the ink applied thereto has dried, the material is next sized by the application of a suitable sizing material to the burlap side thereof which serves the joint purpose of fixing and anchoring the projecting ends of the fibrous material punched through the interstices of the burlap and at the same time, by subsequent ironing or calendering, producing a glazed, smooth and finished appearance on the surface thereof. This sizing be readily and cheaply applied to the interior walls of automobiles or the compartments thereof without additional nnishing.

As showing a specific example of the present invention, reference mayv be had to the accompanying drawing in which; V

Figure 1 is a perspective view of a sheet or strip of felted material of the type suitable for use in making material of this invention;

Figure 2 is a perspective view of the material shown in Figure 1, in which contrasting or blending colors are employed for the bers and the burlap backing strip, respectively;

Figure 3 is a perspective view of the felted material shown in Figures 1 or 2 having a cross slash marking printed on the burlap surface thereof and `Figure 4 is a perspective view of the material printed as shown in Figure 3 having in addition, a plaid stripe printed over the diagonal slash marking.

As shown in the drawing the invention as here illustrated utilizes as a base material, a strip or sheet of felt I0, comprising a mat or layer of felted fibers I I, which may be of jute, hair or any other suitable material of the type employed for making felt materials. This strip is provided with a backing strip I2 of burlap or other suitable fabric, preferably of a loose, open Weave and relatively inexpensive in character.

Felt material of the type shown in Figure 1 is `now supplied on the market and its method of manufacture is known and understood by those skilled in this art and therefore a detailed description will not'be here given. However, it is known that the fibers are fed upon the burlap strip and are compacted and felted by the punching action of a group of needles which in addition to felting the fibers, cause certain portions thereof to project through the interstices of the burlap backing strip. This is represented in Figure 1 of the drawing at I3.

In making this material, the fibers and the backing sheet may be given the desired color by dyeing or other suitable coloring process so that a contrasting or blending color appearance may be imparted to the material. The nbers may be light on a dark background of burlap or vice versa, or both the fibers and burlap may be dyed different shades of somewhat the same color.

Of course it is to be understood also, that either the fibers or the backing sheet may be leftin its natural c'olor and employed with a contrasting color given to the bers or a backing strip, as the case may be.

The material prepared either with the bers and backingvsheet of the same color as shown in Figure 1, or of contrasting or blending colors as shown in Figure 2 and while in a soft flexible condition, is next subjected to a printing operation by means of rolls or other suitable printing device for applying thereto suitable markings such as the diagonal slash lines I5, shown in Figure 3. These slash lines are such as to impart to the material an appearance similar to that characteristic of woven fabric. In place of the diagonal slash lines, other markings, such as herringbone markings, or other typical woven patterns may be employed so that as aresult, the combined appearance of the actual weave of the threads of the burlap and the slash or other markings placed thereon, give to the whole, the appearance of a woven fabric of heavy and good quality.

In addition to the printed markings above described, a further printed marking may be placed thereon such as for instance, the plaid marking I6, shown in Figure 4. This may be in a similar or different color from the marking shown in Figure 3 and in addition, the various stripes of the plaid may bein different or similar colors.

Furthermore, it is to be understood that the printing of thematerial may include any number of suitable marking operations in any desired combination of patterns and colors so as to give the desired nnished effect which in combination with the natural weave of the burlap strip will give to the whole, the appearance of a heavy fabric.

After the printing has been completed, the material is next subjected to a drying operation after which it is next treated with a size on the burlap side thereof. Any suitable size may be employed such as latex, glue, starch, or other suitable sizing now known and used in industry, and which may be subsequently heat treated and/or ironed or calendered so as to impart to the printed burlap surface, a glazedsemistiff finished appearance. If latex is employed as the sizing material, not only is the desired nish imparted to the surface but in addition, a very durable, elastic bond is formed for holding the fibrous ends I3 which projectI through the burlap strip. The anchoring of the fibrous ends through the burlap strip is also the function of any sizing material thatmay be employed.

From insulating and sound deadening material so produced, panels may be cut of the desired shape and size adapted to be readily applied to the interior walls of automobile bodies. Panels thus formed can be quickly and easily applied directly to the interior walls of the body Without requiring any covering or finishing material as now employed in connection with the linings used in automobiles. 'I'he material of this invention and thepanels made therefrom have a very pleasing appearance and thus provide a suitable finish without utilizing expensive surfacing materials. t

It is apparent that this material, due to its felted fibers, is an excellent sound deadening and heat insulating material which has imparted thereto, a desirable surface appearance by very simple and inexpensive manufacturing steps. This material is thus made very cheap and can be employed with a high degree of satisfaction in a number of uses where much more expensive materials are now required.

I claim:

1. A sound deadening and insulating material comprising a layer of felted fibers and a strengthening Web of loosely woven cloth, said layer of felted bers being needled to said web in such manner as to leave said cloth on one face of said layer with its threads plainly visible thereon, and printed markings on said woven cloth of such character as to preserve the visibility of threads comprising said cloth and at the same time producing with said visible threads the appearance of a heavy woven fabric, and a coating of size on said woven cloth rendering said material semi-rigid while imparting to the marked surface thereof, a glazed, finished appearance.

2. A sound deadening and insulating material comprising a layer of felted bers and a strengthening web of burlap, said layer of felted fibers being needled to said burlap in such manner as to leave said burlap on one face of said layer with its threads plainly visible thereon, and printed markings on said burlap of such character as to preserve the visibility of the threads comprising said burlap and at the same time producing with said visible threads, the appearance of a heavy Woven fabric and a coating of size on said burlap rendering said material semirigid while imparting to the marked surface thereof, a glazed, finished appearance.

3. A sound deadening and insulating material comprising a layer of felted fibers and a strengthening web of loosely woven cloth, said layer of felted fibers being needled to said web in such manner as to leave said cloth on one face of said layer with its threads vplainly visible thereon, said fibers and cloth having contrasting or blending colors, and printed markings on said woven cloth of such character as to preserve the visibility of the threads comprising said cloth and at the same time, producing with said visible threads, the appearance of a heavy woven fabric and a coating of size on said woven cloth rendering said material semi-rigid While imparting to the marked surface thereof, a glazed, finished appearance.

4. A sound deadening and insulating panel for lining automobile bodies and the like, comprising a layer of felted fibers and a strengthening web of loosely woven cloth, said layer of felted fibers being needled to said web in such manner as to leave said cloth on one face`of said layer with its threads plainly visible thereon, and printed markings on said woven cloth of such character as to preserve the visibility of the threads comprising said cloth and at the same time producing with said visible threads the appearance of a heavy woven fabric, and a coating of size on said woven cloth rendering said material semirigid while imparting to the marked surface thereof, a glazed, finished appearance.

5. A sound deadening and insulating panel for lining automobile bodies and the like, comprising a layer of felted fibers and a strengtheningweb of burlap, said layer of felted fibers being needled to said burlap in such manner as to leave said burlap on one face of said layer with its threads plainly visible thereon, and printed markings on said burlap of such character as to preserve the visibility of the threads comprising said burlap and at the same time producing with said visible threads, the appearance of a heavy Woven fabric and a coating of size on said burlap rendering said material semi-rigid while imparting to the marked surface thereof, a glazed, iinished appearance.

6. A sound deadening and insulating panel for lining automobile bodies and the like, comprising a layer of felted fibers and a strengthening web of loosely woven cloth, said layer of felted bers being needled to said web in such manner as to leave said cloth on one face of said layer with its threads plainly visible thereon, said fibers and cloth having contrasting or blending colors, and printed markings on said woven cloth of such character as to preserve the visibility of the threads comprising said cloth and at the same time, producing with said visible threads, the appearance of a heavy Woven fabric and a coating of size on said woven cloth rendering said material semi-rigid While imparting to the marked surface thereof, a glazed, finished ap- 

